Apparatus and methods for separating a sheet of media from other sheets of media for feeding the separated sheet of media to a media processor

ABSTRACT

A method of feeding a sheet of media to a media processor is provided. The method may include picking up the sheet of media from a stack of sheets. The method may further include curling the picked-up sheet of media to separate the picked-up sheet of media from other sheets of media in the stack of sheets. In addition, the method may include feeding the curled sheet of media to the media processor.

BACKGROUND OF THE INVENTION

[0001] I. Field of the Invention

[0002] The present invention generally relates to the field of media processors, such as film digitizers, scanners, and printers. More particularly, the invention relates to apparatus and methods for separating a sheet of media from other sheets of media for feeding the separated sheet of media to a media processor.

[0003] II. Background and Material Information

[0004] Increasingly, high-volume processing of media by a media processor, such as an X-ray film digitizer is desirable. To accomplish this goal, typically sheets of media, such as X-ray films, may be stacked, for example, in a tray. A sheet feeding mechanism may then feed one sheet at a time to the media processor. There have been many problems, however, in feeding the sheets one at a time to the media processor. For example, the sheets may stick to each other because of static or because of the vacuum created between the successive sheets. Such problems are exacerbated in media such as X-ray films, transparencies, or such similar media.

[0005] Previous attempts at feeding the sheets one at a time have only been marginally successful. Indeed, most feeding mechanisms offer poor reliability in separating sheets for feeding them one at a time.

[0006] Accordingly, there is a need for improved methods and apparatus for separating a sheet of media from other sheets of media and feeding the separated sheet of media to a media processor.

SUMMARY OF THE INVENTION

[0007] Apparatus and methods consistent with embodiments of the present invention provide for feeding a sheet of media to a media processor in a way that only one sheet is fed at a time to the media processor.

[0008] According to one embodiment of the invention, a method of feeding a sheet of media to a media processor is provided. The method may include picking up the sheet of media from a stack of sheets. The method may further include curling the picked-up sheet of media to separate the picked-up sheet of media from other sheets of media in the stack of sheets. In addition, the method may include feeding the curled sheet of media to the media processor.

[0009] According to another embodiment of the invention, a media feeder for a media processor is provided. The media feeder may include a first drive system and a pulley coupled to the first drive system. The media feeder may further include a bar including at least one suction cup. The media feeder may also include at least one linkage connecting the pulley to the bar such that rotation of the pulley by the first drive system moves the bar toward a stack of sheets of film so that the at least one suction cup grips a single sheet of film from the stack of sheets. Additionally, the media feeder may include a linear member arranged to hold the single sheet of film down such that the gripped single sheet of film curls.

[0010] According to yet another embodiment of the invention, an apparatus for feeding a single sheet of film from a stack of sheets of film to a media processor is provided. The apparatus may include a first surface and a second surface arranged concentrically outside the first surface, wherein the second surface may have a plurality of perforations therethrough. The apparatus may further include a suction cup formed at each perforation of at least a subset of the plurality of perforations. The apparatus may also include a pump configured to create an air flow through at least the subset of the plurality of perforations such that a single sheet of film from the stack of sheets is pulled toward the second surface. In addition, the apparatus for feeding the single sheet of film may include a linear member arranged to hold the pulled single sheet of film down such that the pulled single sheet of film curls.

[0011] According to still another embodiment of the invention, an apparatus for feeding a single sheet of media to a media processor is provided. The apparatus may include a drive system and a coupling assembly connecting the drive system to at least one suction cup, whereby the drive system moves the at least one suction cup to lift the single sheet of media.

[0012] Both the foregoing general description and the following detailed description are exemplary and are intended to provide further illustration and explanation of the embodiments of the invention as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate various embodiments and aspects of the present invention. In the drawings:

[0014]FIG. 1 illustrates an exemplary system environment consistent with embodiments of the present invention;

[0015]FIG. 2 is a front perspective view of an exemplary media feeder consistent with embodiments of the present invention;

[0016]FIG. 3 is a front perspective view of the exemplary media feeder of FIG. 2 at a different point of operation;

[0017]FIG. 4 is a front perspective view of another exemplary apparatus for feeding a sheet of media to a media processor consistent with embodiments of the present invention;

[0018]FIG. 5 is a front perspective view of another exemplary apparatus for feeding a sheet of media to a media processor consistent with embodiments of the present invention;

[0019]FIG. 6 is a flowchart for an exemplary method of feeding a sheet of media to a media processor consistent with embodiments of the present invention; and

[0020]FIGS. 7A, 7B, and 7C show curling of a sheet of media consistent with embodiments of the present invention.

DETAILED DESCRIPTION

[0021] Apparatus and methods consistent with embodiments of the present invention relate to apparatus and methods for separating a sheet of media from other sheets of media for feeding the separated sheet of media to a media processor.

[0022]FIG. 1 illustrates an exemplary system environment, consistent with embodiments of the present invention. As shown, a media processor 102 may be connected to a workstation 104. Media processor 102 may be a scanner, a digitizer, or any other apparatus that may be used to scan or digitize paper, film, photographic paper, or X-ray film. Workstation 104 may be used to store and view an image acquired by media processor 102. Media processor 102 may include a housing 106 and a tray containing media 108. Thus, for example the tray may contain sheets of film, such as X-ray film.

[0023] As shown in FIG. 2, a feed mechanism may comprise an internal housing 202, a first drive system 204 (for example, a motor), which may then be coupled to a pulley 206, a linkage 208 connecting the pulley to a bar 210, which may have at least one suction cup 212 mounted thereon. As shown in FIG. 2, bar 210 may have another suction cup 214 mounted on it. Indeed, in other embodiments consistent with the present invention more than two suction cups may be mounted on a bar or a similar structure in order to support the suction cups. First drive system 204 may provide power to rotate the pulley 206. First drive system 204 may be a stepper motor or any other type of motor that may be used to control the movement of the bar 210. Also, first drive system 204 may be coupled to the bar 210 using other mechanisms, such as gears or any other mechanism for translating the torque from the first drive system to the arc-like movement of the bar 210.

[0024] In one embodiment, at least one linkage 208 may connect pulley 206 to bar 210, such that rotation of pulley 206 by first drive system 204 moves bar 210 toward a stack of sheets of media so that at least one suction cup (212, 214) grips a single sheet of media. In one embodiment, linkage 208 may include at least two bars. Alternatively or additionally, other structures may be used to couple first drive system 204 to bar 210, such that rotation of pulley 206 moves bar 210 toward the stack of sheets of media. Additionally, rotation of pulley 206 by first drive system 204 may also move bar 210 away from the stack of sheets of media in an arcuate manner.

[0025] In one embodiment, bar 210 may be positioned as shown in FIG. 3 to pick up a sheet of media. When in this position, at least one suction cup (212, 214) may contact the sheet of media and a slight pressure on bar 210 may cause a vacuum to develop between the at least one suction cup and the sheet of media. This vacuum may result in a grip of the suction cups on the sheet of media. Alternatively, the vacuum between the suction cups and the sheet of media may be generated by connecting a pump (not shown) configured to create an airflow through the suction cups such that the vacuum is formed between the suction cups and the sheet of media. In other words, suction can be created by active pumping or other passive means. It should be appreciated that several suction cups may be connected to a single vacuum pump or each suction cup may be connected to a separate pump.

[0026]FIG. 4 shows an exemplary apparatus for feeding a sheet of media to a media processor consistent with embodiments of the present invention. As shown in FIG. 4, once at least one suction cup (212, 214) grips a single sheet of media (as it is lifted or curled), it may be engaged by at least one roller (234, 236) configured to engage the single sheet of media and feed the single sheet of media to the media processor. The at least one roller (234, 236) may be coupled to a second drive system (not shown) via, for example, member 230. Although not shown in FIG. 4, any means of coupling a roller to a drive system may be used, for example, a pulley, a belt, a set of gears, or the like.

[0027] The apparatus for feeding the sheet of media to the media processor may further include at least one idler roller 240. Idler roller 240 may be configured to form a drive nip between idler roller 240 and at least one roller 234, 236.

[0028] Further, the apparatus shown in FIG. 4 may include a spring 220 configured to hold down a corner of the single sheet of media. One skilled in the art will appreciate that other equivalent structures such as a flexible bar or other structures that may hold down the corner of the single sheet of media may be used consistent with the present invention.

[0029]FIG. 5 shows another exemplary apparatus for feeding a sheet of media to a media processor consistent with embodiments of the present invention. As shown, the exemplary apparatus may include a first surface 502 and a second surface 504 arranged concentrically outside first surface 502. Second surface 504 may have a plurality of perforations (506, for example) therethrough. Further, at least one suction cup 508 may be formed at each perforation of at least a subset of the plurality of perforations. Although FIG. 5 depicts spherical surfaces, other shapes of surfaces may also be used consistent with the present invention.

[0030] Further, a pump 510, for example, may be configured to create an air flow through at least the subset of plurality of perforations such that a single sheet of media from the stack of sheets is pulled toward the second surface. Further, although not shown in FIG. 5, a linear member may be arranged to hold the pulled singled sheet of media down such that the pulled single sheet of media curls.

[0031]FIG. 6 shows a flowchart for an exemplary method of feeding a sheet of media to a media processor. The method may include picking up a sheet of media from a stack of sheets (step 602). In one embodiment, at least one suction cup 212, 214 (FIG. 2) may be used to grip the sheet of media. Alternatively, at least one suction cup 506 (FIG. 5) may form a grip onto the sheet of media. Additionally, other means for picking up a sheet of media may be used, such as a vacuum chuck, a sticky roller, and/or a mechanical grabber.

[0032] The method may further include curling the picked-up sheet of media to separate the picked-up sheet of media from other sheets of media in the stack of sheets (step 604). In one embodiment, a linear member (a cross-sectional view of which is shown, for example, in FIGS. 7A-C) may be arranged to hold the gripped sheet of media, such that the sheet of media curls. Alternatively or additionally, a spring 220 (FIG. 4) may be used to hold down a corner of the sheet of media and thereby causing the sheet of media to curl. Although a linear member is shown (for example in FIGS. 7A-C) to hold down the sheet such that a sheet curls, other structures may also be used to achieve the same result. Also, the sheet of media may be curled either lengthwise or widthwise. Indeed, the sheet of media may need to be curled in different ways (for example, both widthwise and lengthwise and/or diagonally) and/or several times in at least one way. Further, the linear member or any other device used to curl the sheet of media may keep the sheet of media from moving prematurely in a longitudinal direction.

[0033] Next, the method may include feeding the curled sheet of media to the media processor (step 606). In one embodiment, this may be accomplished using, for example, at least one roller 234, 236 (FIG. 4) or both in combination with an idler roller 240. Thus, for example, in one embodiment, at least one roller 234 and idler roller 240 may form a nip between them and thereby grab the curled sheet of media.

[0034]FIGS. 7A, 7B, and 7C show curling of a sheet of media consistent with embodiments of the present invention. As shown in FIG. 7A, initially a sheet of media may be flat. A cross sectional view of a linear member 702 arranged to hold down the single sheet of media is depicted as well. Once gripped by at least one suction cup, movement of the at least one suction cup may curl the sheet of media (FIG. 7B). Additional movement of the at least one suction cup may further curl the single sheet of media and in the process separate it from other sheets of media (FIG. 7C). Next, although not shown, linear member 702 may be lifted up by a mechanism coupled to a motor, for example, permitting a pick-up device, such as the at least one suction cup, to pick up the single sheet of media.

[0035] Additionally, in one embodiment, the method may further include detecting one or more abnormal events while attempting to pick up a sheet of media. The abnormal events may include at least situations where no sheet of media is picked up or where more than one sheet of media is picked up. In one embodiment, no sheet of media being picked up may be detected when a large vacuum leak is detected by, for example, a pump used to create a vacuum between the suction cups and the sheet of media. Alternatively, an optic sensor or a Hall effect sensor may also be used to detect a situation where no sheet of media was picked up by a suction cup. An abnormal event where more than one sheet of media is picked up by the media processor may be detected using, for example, a small vacuum leak created by the lack of curling of multiple sheets when being curled together. Alternatively, any sensor capable of detecting a thickness of the picked up sheets may be used. Such sensors include an optic sensor or a Hall effect sensor. Also, a sensor that may detect a bending moment of the one or more sheets of media being curled may also be used to detect an abnormal event

[0036] Other modifications and embodiments of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. 

What is claimed is:
 1. A method of feeding a sheet of media to a media processor, the method comprising: picking up the sheet of media from a stack of sheets; curling the picked-up sheet of media to separate the picked-up sheet of media from other sheets of media in the stack of sheets; and feeding the curled sheet of media to the media processor.
 2. The method of claim 1, wherein the sheet of media is an X-ray film.
 3. The method of claim 1, wherein the sheet of media is one of a sheet of paper, a sheet of transparency, and a sheet of photographic paper.
 4. The method of claim 1, wherein curling the picked-up sheet of media further includes curling the sheet of media in a lengthwise direction.
 5. The method of claim 4, further comprising curling the sheet of media at least one more time in the lengthwise direction.
 6. The method of claim 1, wherein curling the picked-up sheet of media further includes curling the sheet of media in a widthwise direction.
 7. The method of claim 6, further comprising curling the sheet of media at least one more time in the widthwise direction.
 8. The method of claim 1, wherein curling the picked-up sheet of media further includes curling the sheet of media in both a lengthwise direction and a widthwise direction.
 9. The method of claim 1, further comprising detecting at least one abnormal picking event.
 10. The method of claim 9, wherein the at least one abnormal event comprises at least one of no sheet of media picked and more than one sheet of media picked.
 11. A media feeder for a media processor, comprising: means for picking up a sheet of media from a stack of sheets; means for curling the picked-up sheet of media; and means for feeding the curled sheet of media to the media processor.
 12. The media feeder of claim 11, wherein the sheet of media is an X-ray film.
 13. The media feeder of claim 11, wherein the sheet of media is one of a sheet of paper; a sheet of transparency, and a sheet of photographic paper.
 14. The media feeder of claim 11, wherein said means for curling the picked-up sheet of media further includes means for curling the sheet of media in a lengthwise direction.
 15. The media feeder of claim 11, wherein said means for curling the picked-up sheet of media further includes means for curling the sheet of media in a widthwise direction.
 16. The media feeder of claim 11, wherein said means for curling the picked-up sheet of media further includes means for curling the sheet of media in both a lengthwise direction and a widthwise direction.
 17. The media feeder of claim 11, further comprising means for detecting at least one abnormal picking event.
 18. The media feeder of claim 17, wherein the at least one abnormal event comprises at least one of no sheet of media picked and more than one sheet of media picked.
 19. The media feeder of claim 11, wherein the means for picking up a sheet of media from the stack of sheets includes at least one of a vacuum chuck, a sticky roller, and a mechanical grabber.
 20. A media feeder for a media processor, comprising: a first drive system; a pulley coupled to the first drive system; a bar including at least one suction cup; at least one linkage connecting the pulley to the bar such that rotation of the pulley by the first drive system moves the bar toward a stack of sheets of film so that the at least one suction cup grips a single sheet of film from the stack of sheets; a linear member arranged to hold the single sheet of film down such that the single sheet of film curls.
 21. The media feeder of claim 20, further comprising: at least one roller configured to engage the single sheet of film and feed the single sheet of film to the media processor.
 22. The media feeder of claim 21, further comprising: a second drive system to drive the at least one roller.
 23. The media feeder of claim 21, further comprising: at least one idler roller.
 24. The media feeder of claim 20, further comprising: a spring configured to hold down a corner of the single sheet of film.
 25. The media feeder of claim 20, wherein rotation of the pulley by the first drive system moves the bar away from the stack of sheets of film in an arcuate manner.
 26. The media feeder of claim 20, wherein the single sheet of film is the top sheet of film.
 27. The media feeder of claim 20, wherein the linear member is arranged to hold the single sheet of film such that as the at least one suction cup pulls the single sheet of film from the stack of sheets the single sheet of film curls.
 28. An apparatus for feeding a single sheet of media from a stack of sheets of media to a media processor, comprising: a first surface; a second surface arranged concentrically outside the first surface, the second surface having a plurality of perforations therethrough; at least one suction cup formed at each perforation of at least a subset of the plurality of perforations; a pump configured to create an air flow through at least the subset of the plurality of perforations such that a single sheet of media from the stack of sheets is pulled toward the second surface; and a linear member arranged to hold the pulled single sheet of media down such that the pulled single sheet of media curls.
 29. The apparatus of claim 28, further comprising: at least one roller configured to engage the single sheet of media and feed the single sheet of media to the media processor.
 30. The apparatus of claim 29, further comprising: a second drive system configured to drive the at least one roller.
 31. The apparatus of claim 29, further comprising: at least one idler roller configured to form a nip between the at least one roller and the at least one idler roller.
 32. The apparatus of claim 28, further comprising: a spring configured to hold down a corner of the single sheet of media.
 33. The apparatus of claim 28, wherein the linear member is arranged to hold the single sheet of media down such that as the at least one suction cup pulls the single sheet of media from the stack of sheets of media the single sheet of media curls.
 34. An apparatus for feeding a single sheet of media to a media processor, the apparatus comprising: a drive system; and a coupling assembly connecting the drive system to at least one suction cup, whereby the drive system moves the at least one suction cup to lift the single sheet of media.
 35. The apparatus of claim 34, further comprising: a member arranged to hold the single sheet of media such that the single sheet of media curls.
 36. The apparatus of claim 34, further comprising: at least one roller configured to engage the single sheet of media and feed the single sheet of media to the media processor.
 37. The apparatus of claim 34, further comprising: at least one idler roller configured to form a nip between the at least one roller and the at least one idler roller.
 38. The apparatus of claim 34, wherein the sheet of media is one of an X-ray film, a sheet of paper, a sheet of transparency, and a sheet of photographic paper.
 39. The apparatus of claim 34, further comprising: a spring configured to hold down a corner of the single sheet of media.
 40. The apparatus of claim 35, wherein the member is arranged to hold the single sheet of media such that the single sheet of media curls as the at least one suction cup lifts the single sheet of media. 